Non-woven, fracture reducing brake rotor preforms and pads

Abstract

The present disclosure describes brake rotor preforms and brake pads configured to reduce fracturing and failure of brake rotors by distributing the axial force applied during braking across butt joints between abutting segments of preforms and rotors manufactured therefrom. The preforms comprise a spiral annular structure formed about a longitudinal axis from a plurality of carbon fiber precursor tow segments having a partial annular shape. Each segment is asymmetrical when viewed in the longitudinal axis direction and configured so planes defined by the segment's ends are never coplanar with planes extending radially from the longitudinal axis. The brake pads have a partial annular shape and ends adapted to prevent planes defined by the ends from being coplanar during use with a plane extending radially from a brake rotor longitudinal axis.

What is claimed is: 
     
       1. A brake rotor preform from which a vehicle brake rotor is manufactured, comprising:
 a plurality of segments of carbon fiber precursor configured end-to-end in a helical structure having a central longitudinal axis, wherein each segment of said plurality of segments has an outer edge at a first radius relative to said central longitudinal axis and an inner edge at a second radius relative to said central longitudinal axis, wherein each segment of said plurality of segments has a first end extending between said inner and outer edges and defining a single first plane, wherein each segment of said plurality of segments has a second end extending between said inner and outer edges and defining a single second plane, and wherein neither of said first plane nor said second plane are coplanar with any plane extending radially from and including said central longitudinal axis. 
 
     
     
       2. The brake rotor preform of  claim 1 , wherein said first plane intersects with a plane extending radially from and including said central longitudinal axis only along a line extending parallel to said central longitudinal axis, and wherein said second plane intersects with a plane extending radially from and including said central longitudinal axis only along a line extending parallel to said central longitudinal axis. 
     
     
       3. The brake rotor preform of  claim 1 , wherein said first end has a length and said second end has a length, and wherein said length of said first end has a measure equal to the measure of said length of said second end. 
     
     
       4. The brake rotor preform of  claim 3 , wherein said first plane defines a first angle relative to a plane tangent to said outer edge at the intersection of said outer edge and said first end, wherein said second plane defines a second angle relative to a plane tangent to said inner edge at the intersection of said outer edge and said second end, and wherein said first angle has a measure equal to the measure of said second angle. 
     
     
       5. The brake rotor preform of  claim 1 , wherein a segment of said plurality of segments comprises carbon fiber precursor tow oriented in a chordal direction of said segment. 
     
     
       6. The brake rotor preform of  claim 1 , wherein a segment of said plurality of segments comprises carbon fiber precursor tow oriented in a radial direction of said segment. 
     
     
       7. The brake rotor preform of  claim 1 , wherein a segment of said plurality of segments comprises carbon fiber precursor tow oriented in a direction defining an angle relative to a chordal direction of said segment, and wherein said angle has an angular measure between five degrees and thirty-five degrees. 
     
     
       8. The brake rotor preform of  claim 1 , wherein a segment of said plurality of segments comprises carbon fiber precursor tow oriented in a direction defining defining an angle relative to a chordal direction of said segment, and wherein said angle has a positive or negative angular measure. 
     
     
       9. A brake rotor preform from which a vehicle brake rotor is manufactured, comprising:
 a plurality of segments of carbon fiber precursor material arranged in a spiral structure having a central longitudinal axis such that each segment of said plurality of segments is radially offset relative to said central longitudinal axis, wherein each segment of said plurality of segments has a partial annular shape when viewed in the longitudinal direction of said central longitudinal axis and has first and second ends, wherein segments of said plurality of segments are arranged end-to-end about said central longitudinal axis and form respective butt joints therebetween, and wherein said respective butt joints define respective single planes not coplanar with planes extending radially from and including said central longitudinal axis. 
 
     
     
       10. The brake rotor preform of  claim 9 , wherein said planes defined by said respective butt joints extend parallel to and absent inclusion of said central longitudinal axis. 
     
     
       11. The brake rotor preform of  claim 9 , wherein said spiral structure includes a plurality of flights formed respectively by consecutive segments of said plurality of segments arranged end-to-end, and wherein each flight of said plurality of flights comprises segments formed from carbon fiber precursor tow material oriented in the same direction. 
     
     
       12. The brake rotor preform of  claim 9 , wherein said spiral structure includes a plurality of flights formed respectively by consecutive segments of said plurality of segments arranged end- to-end, wherein one flight of said plurality of flights comprises segments formed from carbon fiber precursor tow material oriented in a first direction, wherein another flight of said plurality of flights comprises segments formed from carbon fiber precursor tow material oriented in a second direction, and wherein said first direction is different from said second direction. 
     
     
       13. The brake rotor preform of  claim 9 , wherein said spiral structure includes a plurality of flights formed respectively by consecutive segments of said plurality of segments arranged end- to-end, and wherein a flight of said plurality of flights comprises segments formed from carbon fiber precursor tow material oriented in a chordal direction. 
     
     
       14. The brake rotor preform of  claim 9 , wherein said spiral structure includes a plurality of flights formed respectively by consecutive segments of said plurality of segments arranged end- to-end, and wherein a flight of said plurality of flights comprises segments formed from carbon fiber precursor tow material oriented in a radial direction. 
     
     
       15. A vehicle brake pad for use with a vehicle brake rotor, comprising:
 a member having an inner arcuate edge and an outer arcuate edge, having a first end extending between said inner and outer arcuate edges, and having a second end extending between said inner and outer arcuate edges; 
 wherein said first end and said second end are configured so as to never align during use with a plane extending radially from and including a central longitudinal axis of a vehicle brake rotor.